Power-Limiting Cables

Power-Limiting 1. Self- Regulating 2. Power- Limiting This section provides general design guidelines for power-limiting heat-tracing systems installed on insulated metal pipes. For other applications or design assistance, contact your Tyco Thermal Controls representative or phone Tyco Thermal Controls at (800) 545-6258. Also, visit our Web site at www.tycothermal.com. 3. Mineral Insulated 4. Longline Introduction Power-Limiting Technology Contents Introduction..............................................................1 Power-Limiting Technology...............................................1 System Overview..........................................................2 Typical Power-Limiting System.............................................2 Approvals and Certifications...............................................2 Thermal Design...........................................................3 Cable Selection.....................................................3 Bill of Materials............................................................8 Determining the Total Length of Cable.................................8 Electrical Design.......................................................11 Connection Kit Selection and Accessories....................................13 Tyco Thermal Controls power-limiting heating cables are the preferred technology for applications requiring high power output at elevated temperatures. Raychem brand VPL can be used for high maintain temperatures ranging up to 455 F (235 C), depending on cable selection, and exposure temperatures to 500 F (260 C). VPL also can provide a cost-effective alternative to self-regulating heating cables when more than a single run of cable is required (trace ratio > 1). Tyco Thermal Controls power-limiting cables have been certified for use in hazardous and nonhazardous locations. Tyco Thermal Controls power-limiting cables are parallel heating cables formed by a coiled resistor alloy heating element wrapped around two parallel bus wires. At a fixed distance, the insulation is removed from one of the bus wires. The process is repeated, removing the insulation from the other bus wire. This distance between contact points forms the heating zone length. 5. Tubing Bundles 6. Tank 7. Snow and Ice 8. Control and Monitoring 9. Heat-Trace Panels 10.Engineered Products 11.Steam- Tracing Systems 12.Technical Data Sheets H56883 2/11 www.tycothermal.com 1 of 18 13.Appendixes 14.Index

POWER-LIMITING CABLES Fluoropolymer outer jacket Fig. 1 cable construction Bus wire connection Jacket Nickel-plated copper bus wire Metal braid Fluoropolymer inner jacket Power-limiting heating element The positive temperature coefficient (PTC) of the heating element reduces power output as ambient temperature increases. This effect allows the power-limiting cable to be crossed over itself since the temperature of the heating element is reduced at the cross over points. System Overview Typical Power-Limiting System A typical power-limiting heating cable system is shown in Figure 2. The heating cable is cut to length at the job site and attached to the pipe with glass tape. A power connection kit connects the heating cable bus wires to power in a junction box. Tees and splices accommodate pipe branches to connect two or three heating cables together. An end seal kit is used to terminate the end of the heating cable. These required connection kits are designed and approved to provide a safe and reliable heat-tracing system. For applications requiring tight temperature control, electrical system monitoring, or remote operation, consider a control and monitoring system. To ground-fault protected power Power connection Splice or tee (as required) Glass tape End seal Pipe strap cable Fig. 2 Typical power-limiting heating cable system Thermal insulation Approvals and Certifications Tyco Thermal Controls self-regulating systems are approved and certified for use in nonhazardous and hazardous locations by many agencies. Please refer to technical data sheets for more details. 2 of 18 www.tycothermal.com H56883 2/11

Thermal Design 1. Self- Regulating Thermal Design Cable Selection The thermal design of a power-limiting heat-tracing system follows the same steps as for a self-regulating system. Refer to Self-Regulating : Thermal Design, to determine the pipe heat loss for your application. The example below can be used to follow the steps for a manual design with VPL powerlimiting heating cables. For an optimized design, use our TraceCalc Pro design software or contact your Tyco Thermal Controls representative. If your application requires a high maintain temperature up to 455 F (235 C), the heating cable selection process involves three basic steps: Gather the following information: Pipe size and material Insulation type and thickness Maintain temperature (T M ) Minimum ambient temperature (T A ) Minimum start-up temperature Service voltage Chemical environment Maximum intermittent exposure temperature* Electrical area classification** Select the heating cable service voltage. Determine the heating cable power output rating. * Determines whether a higher exposure temperature heating cable is needed. ** Determines whether special design requirements and connection kits must be used. For higher maintain temperatures or where more power is required, refer to Mineral Insulated for product selection, or contact your Tyco Thermal Controls representative. If your application is in a hazardous location, you must determine the maximum sheath temperature. Power-limiting heating cables do not have an unconditional T-rating as do selfregulating cables. The maximum sheath temperature of the cable must be calculated to ensure that it is compatible with the hazardous location requirements. Use TraceCalc Pro design software or contact your Tyco Thermal Controls representative. 2. Power- Limiting 3. Mineral Insulated 4. Longline 5. Tubing Bundles 6. Tank 7. Snow and Ice 8. Control and Monitoring 9. Heat-Trace Panels 10.Engineered Products 11.Steam- Tracing Systems 12.Technical Data Sheets H56883 2/11 www.tycothermal.com 3 of 18 13.Appendixes 14.Index

POWER-LIMITING CABLES HEATING CABLE CATALOG NUMBER Before beginning, take a moment to understand the structure underlying heating cable catalog numbers. You will refer to this numbering convention throughout the product selection process. Your goal is to determine the catalog number for the product that best suits your needs. XX VPL X-CT Outer Jacket CT = Fluoropolymer Fig. 3 cable catalog number Voltage 1 = 120 Volt (100 120 Vac) 2 = 240 Volt (200 277 Vac*) 4 = 480 Volt (400 480 Vac) cable family VPL Power output rating (Watts/ft) * 20VPL limited to 240 Vac Cable Selection 1. Gather information 2. Select service voltage 3. Determine power output rating Step Gather the necessary information To select the heating cable, gather and record the following information: Pipe size and material Insulation type and thickness Maintain temperature (T M ) Minimum ambient temperature (T A ) Minimum start-up temperature Service voltage Chemical environment Maximum intermittent exposure temperature* Electrical area classification** Example: Gather necessary information Pipe size and material 2 inch, carbon steel Insulation type and thickness Fiberglass, 3 inch Maintain temperature (T M ) 280 F Minimum ambient temperature (T A ) 40 F Minimum start-up temperature 0 F Service voltage 120 Vac Chemical environment Chlorides Maximum intermittent exposure temperature* 450 F Electrical area classification** Nonhazardous *Determines whether a higher exposure temperature heating cable is needed. **Determines whether special design requirements and connection kits must be used. 4 of 18 www.tycothermal.com H56883 2/11

Cable Selection 1. Self- Regulating Cable Selection 1. Gather information 2. Select service voltage 3. Determine power output rating Step Select the heating cable service voltage Service voltage options: 1 = 120 volts (100 120 Vac) 2 = 240 volts (200 277 Vac*) 4 = 480 volts (400 480 Vac) Example: Service voltage selection Input 120 volts (from Step 1) Catalog number xvpl1-ct * 20VPL limited to 240 Vac 2. Power- Limiting 3. Mineral Insulated 4. Longline Cable Selection 1. Gather information 2. Select service voltage 3. Determine power output rating Step Determine the heating cable power output rating Using Graphs 1 and 2 on page 6 or Graph 3 on page 7, locate the heating cable with thermal output greater than the heat loss (Q T ) at the pipe maintain temperature (T M ). If the pipe heat loss, Q T, is in between the two heating cable power output curves, select the higher-rated heating cable. If Q T is greater than the power output of the highest-rated heating cable, you can: Use two or more heating cables run in parallel. Spiral the heating cable. Use thicker insulation to reduce heat loss. Use insulation material with a lower k factor. 5. Tubing Bundles 6. Tank 7. Snow and Ice Q T = 12.8 W/ft 20VPL 8. Control and Monitoring Fig. 4 cable thermal output T M = 280 F Following the thermal design steps described in the Self-Regulating publication: Q T = 11.8 W/ft + [2/5 x (14.3 11.8)] Q T = 12.8 W/ft Spiraling If spiraling is elected, use the formula below to determine the spiral factor (length of heating cable per foot of pipe): Spiral factor = Q T / Heater power output at T M 9. Heat-Trace Panels 10.Engineered Products 11.Steam- Tracing Systems When the spiral factor exceeds 1.6 or the pipe size is less than three inches, consider using two or more heating cables run in parallel rather than spiraling. Example: Power output selection Input VPL heating cable (determined earlier in this step) Input Power output rating = 20 (determined earlier in this step) Input Heat loss is 12.8 W/ft (from Table 1, Self Regulating Systems, Self- Regulating ) Input 20VPL output of 15.3 W/ft exceeds 12.8 W/ft at 280 F (Graph 1, pg. 6) Catalog number 20VPL1-CT H56883 2/11 www.tycothermal.com 5 of 18 12.Technical Data Sheets 13.Appendixes 14.Index

POWER-LIMITING CABLES Select one of the following graphs based on the voltage determined in Step 1. 5VPL-CT 20 120, 240 and 480 Vac 10VPL-CT 15VPL-CT 20VPL-CT 15 Nominal Output Watts/foot 10 5 0 50 (10) 100 (38) 150 (66) 200 (93) 250 (121) 300 (149) 350 (177) 400 (204) 450 (232) Pipe Temperature F ( C) Graph 2.1 VPL nominal power output at 120 V, 240 V and 480 V 5VPL2-CT 10VPL2-CT 16 208 Vac 14 15VPL2-CT 20VPL2-CT 12 Nominal Output Watts/foot 10 8 6 4 2 50 (10) 100 (38) 150 (66) 200 (93) 250 (121) 300 (149) 350 (177) 400 (204) 450 (232) Pipe Temperature F ( C) Graph 2.2 VPL nominal power output at 208 V 6 of 18 www.tycothermal.com H56883 2/11

Cable Selection 1. Self- Regulating 5VPL2-CT 10VPL2-CT 20 18 277 Vac 2. Power- Limiting 15VPL2-CT 20VPL must not be powered at 277 V Nominal Output Watts/foot 16 14 12 10 8 6 3. Mineral Insulated 4. Longline 5. Tubing Bundles 4 2 0 50 (10) 100 (38) 150 (66) Graph 2.3 VPL nominal power output at 277 V 200 (93) 250 (121) 300 (149) Pipe Temperature F ( C) 350 (177) 400 (204) 450 (232) 6. Tank 7. Snow and Ice 5VPL4-CT 20 10VPL4-CT 15VPL4-CT 480 Vac 8. Control and Monitoring 20VPL4-CT 15 9. Heat-Trace Panels Nominal Output Watts/foot 10 5 10.Engineered Products 11.Steam- Tracing Systems 0 50 (10) Graph 2.4 VPL nominal power output at 400 V H56883 2/11 www.tycothermal.com 7 of 18 100 (38) 150 (66) 200 (93) 250 (121) 300 (149) Pipe Temperature F ( C) 350 (177) 400 (204) 450 (232) 12.Technical Data Sheets 13.Appendixes 14.Index

POWER-LIMITING CABLES Bill of Materials Now that you have selected the correct heating cable for your application, this section helps you to determine: Total length of heating cable required. Electrical design, including circuit breaker sizing and selection. Quantity and type of connection kits and accessories. Determining the Total Length of Cable To determine the total length of heating cable, follow the six steps outlined below. Gather the necessary information: Pipe length and diameter Type and number of valves Type and number of pipe supports Start-up temperature Number of circuits and tees in the piping Calculate the total length of heating cable for the piping. Calculate the total length of heating cable for the valves. Calculate the total length of heating cable for the pipe supports. Include additional heating cable for connection kit installation. Add all the lengths together. cable Extra cable at valves Fig. 5 Typical heating cable layout cable loop for component installation Cable Length 1. Gather information 2. Calculate cable length for piping 3. Calculate cable length for valves 4. Calculate cable length for pipe supports 5. Include cable for connection kits 6. Add all heating cable lengths Step Gather the necessary information Pipe size and diameter Type and number of valves Type and number of pipe supports Start-up temperature Number of circuits and tees in piping Example: Gather necessary information Pipe size and diameter 120 feet of 2-inch pipe Type and number of valves Three 2-inch gate valves Type and number of pipe supports Support shoes, thermally insulated: 10 Start-up temperature 0 F Number of circuits and tees in piping Power connections: 1 End seals: 3 Pipe tees: 2 8 of 18 www.tycothermal.com H56883 2/11

Bill of Materials 1. Self- Regulating Cable Length 1. Gather information 2. Calculate cable length for piping Cable Length 1. Gather information 2. Calculate cable length for piping 3. Calculate cable length for valves 4. Calculate cable length for pipe supports 5. Include cable for connection kits 6. Add all heating cable lengths Cable Length 1. Gather information 2. Calculate cable length for piping 3. Calculate cable length for valves 4. Calculate cable length for pipe supports 5. Include cable for connection kits 6. Add all heating cable lengths Step Calculate the total length of heating cable for the piping Example: Total length of cable for piping calculation 120 ft of pipe (from Step 1) = 120 ft of cable for single tracing Step Calculate the total length of heating cable for the valves Use Table 1 to determine the amount of heating cable required for each valve. Multiply by the number of valves to get the total additional footage of heating cable. Table 1 Recommended Valve Allowances Pipe diameter (IPS) (inches) 1/4 1/2 3/4 1 1-1/4 1-1/2 2 3 4 6 8 10 14 18 24 Example: Total length of cable for valves calculation From Table 1 for a 2-inch diameter pipe, Each valve requires: 4.3 ft Cable needed for three valves: 3 x 4.3 ft Total cable length needed for valves: 12.9 ft Step Calculate the total length of heating cable for the pipe supports SUPPORT SHOES cable feet (meters) 0.3 (0.09) 0.8 (0.2) 1.3 (0.4) 2.0 (0.6) 3.3 (1) 4.3 (1.3) 4.3 (1.3) 4.3 (1.3) 4.3 (1.3) 5.0 (1.5) 5.0 (1.5) 5.6 (1.7) 7.3 (2.2) 9.4 (2.9) 12.6 (3.8) Comments* These recommendations are limited by the amount of heating cable that can physically be installed on small valves. Heat loss may not be fully compensated under extreme conditions. These numbers represent the minimum amount of heating cable required for a service loop. Additional cable may be required to compensate for total heat loss. * Use TraceCalc Pro design software to calculate the exact quantity required for the valve. For each pipe support shoe, calculate the additional heating cable required as follows: Determine the heat loss for one support. Formula: Q SUPPORT = 0.7L x (T M T A ), where L = Support length (ft) (assumes a 0.25-inch steel welded shoe partially shielded from winds) Multiply that heat loss by the total number of supports. Add 10 percent to the total heat loss for added safety. Obtain the heating cable power output per foot from Graph 1 or 2. Divide the total support heat loss by the heating cable power output per foot to get the number of feet of heating cable needed. Example: Total length of cable for pipe supports calculation Input 20VPL1-CT heating cable (from Product Selection, Step 3) Input 10 thermally-insulated shoe supports (from Bill of Materials, Step 1) As the pipe supports are thermally insulated, no additional heating cable is required for this example. H56883 2/11 www.tycothermal.com 9 of 18 2. Power- Limiting 3. Mineral Insulated 4. Longline 5. Tubing Bundles 6. Tank 7. Snow and Ice 8. Control and Monitoring 9. Heat-Trace Panels 10.Engineered Products 11.Steam- Tracing Systems 12.Technical Data Sheets 13.Appendixes 14.Index

POWER-LIMITING CABLES Cable Length 1. Gather information 2. Calculate cable length for piping 3. Calculate cable length for valves 4. Calculate cable length for pipe supports 5. Include cable for connection kits 6. Add all heating cable lengths Step Include additional heating cable for connection kit installation Estimate the number of power connections, tees, and splices for the system. Allow an additional three feet for each connection kit. Example: Include additional cable Input 1 power connection, 3 end seals, 2 tees (from Step 1) Total number of connection kits 6 (from Step 1) Cable needed for 6 connection kits 6 x 3 ft of additional cable Total cable length for 6 connection kits 18 ft of cable Cable Length 1. Gather information 2. Calculate cable length for piping 3. Calculate cable length for valves 4. Calculate cable length for pipe supports 5. Include cable for connection kits 6. Add all heating cable lengths Step Add all the lengths Example: Final addition Cable for piping 120 ft (from Step 1) Cable for valves 12.9 ft (from Step 3) Cable for supports 0 ft (from Step 4) Cable for connection kits 18 ft (from Step 5) Sum of all lengths 120 + 12.9 + 18 = 150.9 ft Total length of heating cable 151 ft (rounded) Now that you have the total length of heating cable you can determine the number of electrical circuits you will need. 10 of 18 www.tycothermal.com H56883 2/11

Bill of Materials 1. Self- Regulating Electrical Design WARNING: Fire hazard There is a danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed. To comply with Tyco Thermal Controls requirements, certifications, and national electrical codes, and to protect against the risk of fire, groundfault equipment protection must be used on each heating cable circuit. Arcing may not be stopped by conventional circuit breakers. DETERMINING MAXIMUM LENGTH OF HEATING CABLE ON ONE CIRCUIT BREAKER Using Tables 2, 3, and 4 match the heating cable catalog number at the expected minimum start-up temperature with the total heating cable length and select a circuit breaker trip rating. The circuit breaker trip rating should not exceed the maximum trip rating shown for heating cables. For example, the trip rating of a circuit breaker protecting several circuits should not exceed 50 amps. To maximize fault current protection, use the lowest allowable circuit breaker sizing. Maximum circuit length per breaker depends on four factors: 1. cable and catalog number 2. Minimum start-up temperature 3. Service voltage 4. Circuit breaker trip rating Table 2 Maximum Circuit Length (feet) vs. Circuit Breaker Trip Rating (Amps) 120- and 240-volt heating cables applied to metal pipe with glass tape Start-up 120-volt cable 240-volt cable cable temperature 15 A 20 A 30 A 40 A 50 A 15 A 20 A 30 A 40 A 50 A 5VPL-CT 50 F (10 C) 260 350 370 370 370 525 685 740 740 740 0 F ( 18 C) 240 325 370 370 370 485 645 740 740 740 20 F ( 29 C) 235 315 370 370 370 470 625 740 740 740 40 F ( 40 C) 225 305 370 370 370 455 610 740 740 740 10VPL-CT 50 F (10 C) 130 175 260 260 260 260 350 525 525 525 0 F ( 18 C) 120 165 245 260 260 245 325 490 525 525 20 F ( 29 C) 120 160 240 260 260 235 315 475 525 525 40 F ( 40 C) 115 155 230 260 260 230 310 465 525 525 15VPL-CT 50 F (10 C) 85 115 175 215 215 175 230 350 430 430 0 F ( 18 C) 80 110 165 215 215 165 220 325 430 430 20 F ( 29 C) 80 105 160 215 215 160 215 320 425 430 40 F ( 40 C) 75 100 155 210 215 155 210 310 415 430 20VPL-CT 50 F (10 C) 65 85 130 175 185 130 175 260 350 370 0 F ( 18 C) 60 85 125 165 185 125 165 250 330 370 20 F ( 29 C) 60 80 120 160 185 120 160 245 325 370 40 F ( 40 C) 60 80 120 160 185 115 155 240 320 370 2. Power- Limiting 3. Mineral Insulated 4. Longline 5. Tubing Bundles 6. Tank 7. Snow and Ice 8. Control and Monitoring 9. Heat-Trace Panels 10.Engineered Products 11.Steam- Tracing Systems 12.Technical Data Sheets H56883 2/11 www.tycothermal.com 11 of 18 13.Appendixes 14.Index

POWER-LIMITING CABLES Table 3 Maximum Circuit Length (feet) vs. Circuit Breaker Trip Rating (Amps) 208- and 277-volt heating cables applied to metal pipe with glass tape Start-up 208-volt cable 277-volt cable cable temperature 15 A 20 A 30 A 40 A 50 A 15 A 20 A 30 A 40 A 50 A 5VPL-CT 50 F (10 C) 589 700 700 700 700 465 620 720 720 720 0 F ( 18 C) 545 700 700 700 700 430 574 720 720 720 20 F ( 29 C) 530 700 700 700 700 418 557 720 720 720 40 F ( 40 C) 515 686 700 700 700 406 541 720 720 720 10VPL-CT 50 F (10 C) 291 388 490 490 490 236 315 472 515 515 0 F ( 18 C) 272 362 490 490 490 221 294 441 515 515 20 F ( 29 C) 265 353 490 490 490 215 286 430 515 515 40 F ( 40 C) 258 344 490 490 490 209 279 419 515 515 15VPL-CT 50 F (10 C) 191 255 383 400 400 160 213 320 420 420 0 F ( 18 C) 180 240 360 400 400 150 200 300 401 420 20 F ( 29 C) 176 234 351 400 400 147 196 293 391 420 40 F ( 40 C) 172 229 343 400 400 143 191 287 382 420 20VPL-CT 50 F (10 C) 142 189 284 340 340 0 F ( 18 C) 135 180 269 340 340 20 F ( 29 C) 132 176 264 340 340 40 F ( 40 C) 129 173 249 340 340 Not permitted (20 VPL must not be powered at 277 V) Table 4 Maximum Circuit Length (feet) vs. Circuit Breaker Trip Rating (Amps) 400- and 480-volt heating cables applied to metal pipe with glass tape Start-up 400-volt cable 480-volt cable cable temperature 15 A 20 A 30 A 40 A 50 A 15 A 20 A 30 A 40 A 50 A 5VPL-CT 50 F (10 C) 756 986 1066 1066 1066 1050 1370 1480 1480 1480 0 F ( 18 C) 698 929 1066 1066 1066 970 1290 1480 1480 1480 20 F ( 29 C) 677 900 1066 1066 1066 940 1250 1480 1480 1480 40 F ( 40 C) 655 878 1066 1066 1066 910 1220 1480 1480 1480 10VPL-CT 50 F (10 C) 380 511 767 767 767 520 700 1050 1050 1050 0 F ( 18 C) 358 475 715 767 767 490 650 980 1050 1050 20 F ( 29 C) 343 460 694 767 767 470 630 950 1050 1050 40 F ( 40 C) 336 453 679 767 767 460 620 930 1050 1050 15VPL-CT 50 F (10 C) 259 340 518 636 636 350 460 700 860 860 0 F ( 18 C) 244 326 481 636 636 330 440 650 860 860 20 F ( 29 C) 237 318 474 629 636 320 430 640 850 860 40 F ( 40 C) 229 311 459 614 636 310 420 620 830 860 20VPL-CT 50 F (10 C) 195 263 390 525 555 260 350 520 700 740 0 F ( 18 C) 188 248 375 495 555 250 330 500 660 740 20 F ( 29 C) 180 176 368 488 555 240 320 490 650 740 40 F ( 40 C) 173 173 360 480 555 230 310 480 640 740 Example: Determining maximum length of heating cable on one circuit breaker Input 20VPL1-CT heating cable (from Product Selection, Step 3) 12 of 18 www.tycothermal.com H56883 2/11

Bill of Materials 1. Self- Regulating Input 120 volts (from Product Selection, Step 1) Input 0 F start-up temperature (from Product Selection, Step 1) Input Maximum circuit length = 165 feet on a 40-amp breaker (from Table 2) If the total length of cable exceeds 165 feet, you must use a 50-amp circuit breaker, which allows up to 185 feet. DETERMINE MINIMUM NUMBER OF CIRCUITS The number of circuits you need depends on the total length of heating cable you will be using and the maximum circuit length for the heating cable you selected. Example: Calculating the minimum number of circuits Input 165 ft allowed per 40-amp circuit (from Table 2) Input Total circuit length = 151 ft (from Bill of Materials, Step 6) Number of circuits 1 circuit If the total length of heating cable required exceeded 165 feet, you would need to split the total length into two separate circuits (or use a larger circuit-breaker size). 2. Power- Limiting 3. Mineral Insulated 4. Longline 5. Tubing Bundles Power Line 1 6. Tank Line 2 Line 3 7. Snow and Ice Connection Kit Selection and Accessories Line 1 + Line 2 + Line 3 Maximum circuit length Fig. 6 Maximum heating cable circuit length Ground-fault protection To minimize the danger of fire from sustained electrical arcing if the heating cable is damaged or improperly installed, and to comply with the requirements of Tyco Thermal Controls, agency certifications, and national electrical codes, ground-fault equipment protection must be used on each heating cable branch circuit. Arcing may not be stopped by conventional circuit protection. Many DigiTrace control and monitoring systems meet the ground-fault protection requirement. 8. Control and Monitoring 9. Heat-Trace Panels 10.Engineered Products WARNING: Fire hazard To prevent fire or shock, Raychem brand specified connection kits must be used. Do not substitute parts or use vinyl electrical tape. OVERVIEW Tyco Thermal Controls offers a full range of connection kits for power connections, splices, and end seals. These connection kits must be used to ensure proper functioning of the product and compliance with warranty, code, and approvals requirements. Different power connection, end seal, splice, and tee kits are required depending on the area classification. The data sheets for these connection kits can be found on the Tyco Thermal Controls Web site, www.tycothermal.com. 11.Steam- Tracing Systems 12.Technical Data Sheets H56883 2/11 www.tycothermal.com 13 of 18 13.Appendixes 14.Index

POWER-LIMITING CABLES NONHAZARDOUS AND HAZARDOUS LOCATION CONNECTION KITS Figure 7 shows the connection kits and accessories available for typical power-limiting systems. JBS-100-ECP-A Nonhazardous locations only E-100-L JBM-100-A T-100 E-100 JBS-100-A T-100 JBM-100-L-A Fig. 7 Power-limiting heating system connection kits and accessories Table 5 Nonhazardous and Hazardous Connection Kit and Accessory Selection Description Catalog number Quantity Connection Kits Power connection 1 per circuit Single heating cable Single heating cable with light Single heating cable with digital electronic controller Single heating cable (user-supplied junction box) Multiple heating cables (1, 2, or 3) Multiple heating cable with light Splice connection JBS-100-A JBS-100-L-A JBS-100-ECP-A (nonhazardous locations only) JS-100-A JBM-100-A JBM-100-L-A Above insulation T-100 Tee connection Above insulation T-100 End seal Above insulation E-100 Above insulation with light E-100-L1-A (100 120 V) E-100-L2-A (200 277 V) Accessories Attachment tape, labels, and pipe straps Controls (optional) Thermostat see Control and Monitoring 1 per splice 1 per tee 1 per power connection plus 1 per tee 14 of 18 www.tycothermal.com H56883 2/11

Bill of Materials 1. Self- Regulating SYSTEM CONNECTION KITS Power Connection Kits for Cable 2. Power- Limiting JBS-100-A JBS-100-A Power connection for one heating cable in nonhazardous and hazardous locations. Includes cold-applied heating cable core seal. Requires one pipe strap to be ordered separately. With red indicator light, order JBS-100-L-A 3. Mineral Insulated 4. Longline JBS-100-ECP-A JBS-100-ECP-A Power connection and digital electronic controller. Requires one pipe strap to be ordered separately. Nonhazardous locations only. 5. Tubing Bundles JS-100-A JS-100-A Junction box stand for one heating cable in nonhazardous and hazardous locations. A separate customer-supplied NEMA 4X junction box is required. Includes cold-applied heating cable core seal. Requires one pipe strap to be ordered separately. 6. Tank JBM-100-A JBM-100-A Multiple-entry power connection for up to three heating cables. Can also be used as a splice or tee connection. For use in nonhazardous and hazardous locations. Includes cold-applied heating cable core seal. Requires two pipe straps to be ordered separately. With red indicator light, order JBM-100-L-A. 7. Snow and Ice 8. Control and Monitoring C75-100-A C75-100-A A NEMA 4X-rated gland kit (3/4" NPT) used to transition heating cables into a junction box in nonhazardous and hazardous locations. Includes cold-applied heating cable core seal. A terminal block (3 x 12 AWG) is included. This kit does not include the junction box or the conduit. 9. Heat-Trace Panels 10.Engineered Products T-100 T-100 Tee or splice connection for up to three heating cables in nonhazardous and hazardous locations. Includes cold-applied heating cable core seal. Requires two pipe straps to be ordered separately. 11.Steam- Tracing Systems E-100-A E-100-A End seal for heating cable in nonhazardous and hazardous locations. Re-enterable. Includes cold-applied heating cable core seal. Requires one pipe strap to be ordered separately. Lighted versions: E-100-L1-A (100 120 V) E-100-L2-A (200 277 V) H56883 2/11 www.tycothermal.com 15 of 18 12.Technical Data Sheets 13.Appendixes 14.Index

POWER-LIMITING CABLES ACCESSORIES GT-66 and GS-54 AT-180 GT-66 Glass Installation Tape For use on pipes other than stainless steel 1/2" x 66' roll Strap at 1-foot intervals at minimum application temperature of 40 F (5 C) GS-54 Glass Installation Tape For use on all pipes, particularly stainless steel 1/2" x 54' roll Strap at 1-foot intervals at minimum application temperature of 40 F ( 40 C) AT-180 Aluminum Tape For use on all pipe materials 2-1/2" x 180' roll Minimum installation temperature: 32 F (0 C) Glass tape across heating cable Aluminum tape over heating cable 1 foot Fig. 8 Tape installation Table 6 Attachment Tape Requirements Rolls needed per 100 ft of cable Pipe diameter (IPS) in inches Tape type 1/2 1 2 3 4 6 8 GT-66 0.6 1.2 4 4 6 8 10 GS-54 0.6 1.4 4 6 6 10 12 AT-180 Use one foot of tape per foot of heating ETL (Electric Traced Label) Attach the label to the outside of the thermal insulation weather barrier to indicate presence of electrical heat tracing. Use one label for every 10 feet (3 m) of pipe, alternating on either ETL side of the pipe. 16 of 18 www.tycothermal.com H56883 2/11

Bill of Materials 1. Self- Regulating Pipe strap Pipe Straps Stainless steel pipe straps to attach connection kits to the heat-traced pipe. Use Table 7 below to assist with pipe strap selection. Table 7 Pipe Strap Selection Catalog number Pipe size PS-01 For conduit 1" PS-03 For connection kits on pipes with dimensions <2" PS-10 For connection kits on pipes with dimensions 2" 10" PS-20 For connection kits on pipes with dimensions 10" 19.5" 2. Power- Limiting 3. Mineral Insulated 4. Longline JBS-SPA Small Pipe Adapters JBS-SPA Adapter for mounting E-100, JBS-100, and JS-100-A to small pipe. 5. Tubing Bundles JBM-SPA JBM-SPA Adapter for mounting JBM-100 and T-100 to small pipe. 6. Tank JB-DRAIN-PLUG-3/4IN Conduit Drain JB-DRAIN-PLUG-3/4IN Conduit drain for JBS-100, JBM-100, and JS-100-A. 7. Snow and Ice Controls For a complete selection of control and monitoring products, including thermostats, see Control and Monitoring. 8. Control and Monitoring DigiTrace 920 9. Heat-Trace Panels DigiTrace 910 NGC-30 system 10.Engineered Products 11.Steam- Tracing Systems 12.Technical Data Sheets NGC-40 system H56883 2/11 www.tycothermal.com 17 of 18 13.Appendixes 14.Index

POWER-LIMITING CABLES 18 of 18 www.tycothermal.com H56883 2/11

Worldwide Headquarters Tyco Thermal Controls 7433 Harwin Drive Houston, TX 77036 USA Tel: 800-545-6258 Tel: 650-216-1526 Fax: 800-527-5703 Fax: 650-474-7711 info@tycothermal.com www.tycothermal.com Canada Tyco Thermal Controls 250 West St. Trenton, Ontario Canada K8V 5S2 Tel: 800-545-6258 Fax: 800-527-5703 Latin America Tyco Thermal Controls 7433 Harwin Drive Houston, TX 77036 United States Tel: 713-868-4800 Tel: 713-735-8645 Fax: 713-868-2333 Europe, Middle East, Africa (EMEA) Tyco Thermal Controls Romeinse Straat 14 3001 Leuven België / Belgique Tel: +32 16 213 511 Fax: +32 16 213 603 Asia Pacific Tyco Thermal Controls 20F, Innovation Building, 1009 Yi Shan Rd, Shanghai 200233, P.R.China Tel: +86 21 2412 1688 Fax: +86 21 5426 2937 / 5426 3167 Tyco, Alliance Integrated Systems, AMC, AutoMatrix, AutoSol, BTV, CapaciSense, Chemelex, DHSX, DigiTrace, DigiTrace logo, DigiTrace Supervisor, Duoterm, ElectroMelt, EM2XR, FHSM, FHSC, FlexFit, FlexiClic, Flowguard, FreezeTrace, FreezGard, Frostex, Flostex Plus, Frostguard, FroStop, FSE, Gardian, HAK, Handvise, HBTV, HCCL, HotCap, HQTV, HTPG, HTPI, HWAT, HXTV, IceStop, Interlock, Isocable, Isodrum, Isoheat, Isomantle, Isopad, Isopad Frostguard, Isopad logo, Isopanel, Isotape, Isotherm, JBM, JBS, K-Flex, K-Flex logo, KHE, KHH, KHL, KHP, KTV, Labsafe, LBTV, LHC, LHFV, LHRV, Metabond, Mini WinterGard, Miser WinterGard, MoniTrace, Multi-plus, NGC, PetroTrace, PLI, PolyMatrix, Pyro CiC, PyroFLX, Pyromaster, Pyropak, Pyrosil, PyroSizer, Pyrotenax, Pyrotenax Designer, Pyrotenax logo, QTVR, QuickNet, QuickNet logo, QuickStat, QuickTerm, RayClic, RaySol, RayStat, Retro WinterGard, RHS, RHSC, RHSM, RMM2, SBF, SBV, SC, SHC, Sheathmaster, ShowerGuard, ShrinkCap, ShrinkSeal, ShrinkSystems, ShrinkTool, ShrinkTube, SLBTV, SnoCalc, SnoCalc logo, STS, System 500, System 1850, System 1850-SE, System 2000, System 2200, T2, T2 logo, T2Blue, T2QuickNet, T2Red, T2Reflecta, TankCalc Plus, TempBus, Thermoheat, ThermoLimit, ThermoLine, Touch, Trac-Loc, TraceCalc, TraceCalc Net, TraceCalc Net logo, TraceCalc Pro logo, TraceGard 277, TraceMaster, Tracer, Tracer logo, TracerLynx, TracerLynx logo, TraceStat, TraceTek, TraceTek logo, TruckPak, VLBTV, VLKTV, VPL, We manage the heat you need, WinterGard, WinterGard logo, WinterGard Plus, WinterGard Wet, XL-Trace, XTV and Zero EMI are registered and/or unregistered trademarks of Tyco Thermal Controls LLC or its affiliates. All other trademarks are the property of their respective owners. 2011 Tyco Thermal Controls LLC Important: All information, including illustrations, is believed to be reliable. Users, however, should independently evaluate the suitability of each product for their particular application. Tyco Thermal Controls makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding its use. Tyco Thermal Controls' only obligations are those in the Tyco Thermal Controls Standard Terms and Conditions of Sale for this product, and in no case will Tyco Thermal Controls or its distributors be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Tyco Thermal Controls reserves the right to make changes without notification to Buyer to processing or materials that do not affect compliance with any applicable specification.